Method for making variegated hard surface coverings



Oct. 5, 1943. 2,331,275 METHOD FOR MAKING VARIEGATED HARD SURFACECOVERINGS A. c. PERRY Filed 001;. 3, 1940 2 Sheets-Sheet l A. C. PERRY IOct. 5, 1943.

' METHOD FOR MAKING VARIEGATED HARD SURFACE COVERINGS Filed 001;. a.1940 2 Sheets-Sheet 2 Patented Oct. 5, 1943 METHOD FOR MAKING VARIEGATEDHARD SURFACE OOVERINGS Arlington C. Perry, Lancaster, Pa., assignor toArmstrong Cork Company, Lancaster, Pa.., a corporation of PennsylvaniaApplication October 3, 1940, Serial No. 359,506

7 Claims.

This invention relates to a method for making variegated hard surfacecovering and more particularly to improvements in the method for makingvariegated linoleum by what is generally termed the cross-rollingprocess.

The cross-rolling process of making variegated linoleum as applied tothe continuous production of linoleum on rotary inlaying machines of theWalton or Batten type contemplates the formation of a sheet having adefinite directional graining commonly called jaspe, overlapping aplurality of such sheets and passing the overlapped sheets through asheeting calender at right angles to the direction of graining thusforming an integral sheet and shortening and spreading the jaspegraining of the face of the sheet to obtain the desired variegationwhich is generally considered to resemble marble. It is known thatgraining produced by this process varies throughout the thickness of thesheet and that the graining of the back of the sheet bears only a remoteresemblance to the graining on the face of the sheet.

One of the chief problems present in such practice resides in thevisible discontinuity between sheets where an overlapped or overlappingsheet adheres to and becomes an integral portion of a following orpreceding sheet. This phenomenon is termed hook-on in the industry andappears to be a visible distortion of face graining which is notcompatible with the required variegation and presents an entirelydifferent appearance at the sections where the overlapped sheets joinone another. The cause of hook on is not known with any degree ofcertainty but it is believed to be due almost entirely to the abruptchange in volume of material present in the nip of the rolls at theoverlapped portions of the sheet and the subsequent flow and surge ofthe plastic material resulting from increased pressure. It may be due inpart to the fact that in some cases the edge portions of the overlappedsheets presented to the calender rolls turn over slightly when subjectedto pressure and thus permit back graining to appear on the face of thesheet. In any event, this visible discontinuity is a. serious distortionof face graining which is undesirable and which annually creates anenormous waste in the production of variegated linoleum on rotaryinlaying machines.

The chief object of my invention is to provide improvements in methodfor making variegated hard surface covering by the cross-rolling processdesigned to eliminate substantially or entirely the visiblediscontinuity present in those portions of the finished sheet whereoverlapped sections join. -An object of my invention is to provide amethod whereby a more satisfactory face variegation may be obtained inthe crossrolling process. A further object is to provide an apparatusfor producing variegated linoleum which is economical in operation andhighly satisfactory in service. A still further object is to obviate theabrupt change in volume of plastic composition at those places where onesheet joins and adheres to a second sheet in the manufacture ofvariegated hard surface covering.

This invention relates to a method of making variegated hard surfacecovering in which the steps comprise. forming a vari-colored mass ofdifferently colored granular compositions, subjecting said mass topressure to form a sheet having a definite directional graining, forminga plurality of openings in said sheet, tearing said sheet along theopenings, so as to form two sections each of which has an irregular edgecomposed of torn and formed portions, overlapping sections so that theirregular edge of one section is disposed adjacent the face of a secondsection, and calendering the overlapped sections to form a continuoussheet.

The attached drawings illustrate a preferred embodiment of my invention,in which Figure 1 is a plan view of my device for making variegated hardsurface covering by the cross-rolling process;

Figure 2 is a view partly in elevation and partly in section of aportion of the device shown in Figure 1, the frame of the device beingremoved to illustrate the skiving and perforating mechanism;

Figure 3 is a view in elevation of a suitable skiving tool;

Fig. 4 is an isometric view of the perforating cutter;

Figure 5 is a sectional view of a sheet of linoleum composition servingto illustrate the skived recess formed in its under surface; and

Figure 6 is an exaggerated plan view of a portion of a sheet providedwith arcuate slots.

Suitable mixing equipment is provided for forming two diiferentlycolored linoleum compositions. It will be appreciated suitable equipmentmay be provided for any desired number of differently coloredcompositions. The difierently colored compositions are blended into acohesive vari-colored mass which is fed to a two-roll sheeting calender2', as shown in Figure l. The face roll 3 of the calender 2 ismaintained at a lower sure that a formed sheet will adhere theretorather than to the back roll 4 and to assist in securing the desiredgrainlng. The roll 3 is rotated at the same or a slightly greater speedthan the roll 4 which extrudes the granules and elongates thedifferently colored granules to some extent thus forming what is knownas a jaspe sheet. A doctor blade (not shown) is usually provided toremove the jaspe sheet from the roll 3. Such equipment is well-known inthe industry and does cross-rolling calender when overlapped sheets are3 Joined and made into an integral sheet. I have foundthat an irregularedge formed by perforating and tearing the edge substantiallyalternately achieves the desired result. I provide a perforating tool orcutter 5 having a plurality of oppositely curved teeth 6 which are bentoutwardly in opposite directions. The cutter B is thus adapted to form aplurality of offset arcuate slots 1 in a formed sheet 8. It will beunderstood, or course, the teeth 6 of the perforating tool 5 may bestraight or curved in the same direction if desired.

Preferably, the tool 5 is disposed adjacent the roll 3 in order thatsuch roll may serve as a platen therefor and is supported by a lever 9pivoted on a shaft I extending across the device.

The lower portion ll of the lever 9 engages and is held in contact witha pin l2 held in a support l3. As the pin I2 is moved outwardly, itrotates the lever 9 about the shaft ID to move the perforating toolupwardly toward the roll 3. As the pin I2 is retracted within thesupport 13, the weight of the perforating tool 5 is suflicient to rotatethe lever 9 about the shaft I 0 thus moving the tool 5 in the oppositedirection. The tool 5 is adjustable laterally of the shaft ill in orderthat the slots 1 may be formed in any desired osition laterally of thesheet 8.

The sheet 8 containing perforations, slots or openings 1 is then ledover a bar M as shown in Figure 1, which serves to tear the sheet intotwo similar sections 8a and 8?) by connecting the offset openings. Thussimilar sections are produced each of which possesses an irregular edgeformed of alternately torn and formed portions. The

sections are placed on a conveyor l5 which carries them to a table 16positioned adjacent the rolls of a cross-rolling calender l1. Suchsections 8a and 8b while traveling on the conveyor are subdivided,either manually or mechanically, into suitable sizes to be fed to thecross-rolling calender H.

The subdivided sheets are disposed in overlapping relation on the tablIS with the irregular edge of one sheet disposed adjacent the face ofthe other sheet. As shown in Figure 1, the subdivided sheets are fed tothe cross-rolling calender l1 face-down and, accordingly, the irregularedge of the sheet is the rear edge. Of course, if a. continuous sheet i8were to be formed faceup, the irregular edge would be that edge of thesheet first fed to the cross-rolling calender. The overlapped sheets arefed to the rolls of the crossrolling calender I! at right angles to thedirection of graining to form a continuous integral sheet i8 and tofurther shorten and spread the grainlng to form variegations on the facethereof which resemble marble.

I have found it'of material aid in the substan- 5 tial elimination of"hook-on" to provide the irregular edge of the sheet with a taperedportion of less thickness than the body of the sheet. This, of course,materially reduces the volume of plastic composition present in the nipof the cross-rolling calender at those points where overlapped sheetsadjoin. In the copending application of Virgil Spencer, Serial No.359,328, filed October 2, 1940, thereis shown a skiving deviceespecially suitable for this purpose. As shown in Figure 2, there isprovided a skivlng tool l9 which serves to skive or form a recess orgroove 20 in the formed Jaspe sheet 8. The skiving tool I9 preferably isdisposed adjacent the roll 3 in order that the roll 3 may serve as aplaten therefor, 20 but it will be understood the tool l9 may be used toskive a groove 28 in the sheet 8 after it has been removed from the roll3. In such case, a suitable backing plate or platen need be provided.The skiving tool I9 skives a thin tapered ribbon from the sheet 8 thusleaving a tapered groove or recess therein.

The skiving tool l9 preferably consists of a thin metal strip 2| havinga sharpened and tapered edge 22 bent into the form shown in Figure 3.

0 The tool i9 is bolted to a metal bar or rod 23 held in a barrel 24adjustably mounted upon a shaft 25 extending across the device. Theskiving tool [9 is adjusted by means of a handwheel 26 secured to athreaded rod 21' which extends through the barrel 24 and into a threadedopening 28 provided in the bar 23. The bar 23 is keyed to the barrel -24to prevent its rotation. Rotation of the handwheel 26 causes rotation ofthe threaded rod 21 permitting the bar 23 to be raised and lowered inthe barrel 24 to move the skiving tool l9 toward andfrom the roll 3,thus varying the depth of the groove or recess skived in the formedsheet.

In operation, a cohesive vari-colored mass of linoleum composition isfed to the two-roll calender 2 and formed into a sheet 8 having adefinite directional graining. While the sheet 8 adheres to the coldroll 3; the skiving tool 19 skives a portion of the under surface ofsuch sheet so as to reduce its thickness, preferably at its centralportion. The perforating tool 5 then, while the sheet still adheres tothe cold roll 3, forms a plurality of slots '1 in the skived portion 20of the sheet 8. The sheet is doctored from the cold roll 3 and passedover a bar [4 which tears it in tWo separate sections 8a and 8b byconnecting the offset slots 7. Each section so formed possesses atapered irregular edge formed of alternate torn and formed portions. Thesections 8a and 8b are placed upon a conveyor l5 which carries them tothe cross-rolling calender l1. During their passage on the conveyor l5,the sections are subdivided, manually or mechanical- 1y, into sheets ofsuitable size for feeding to the cross-rolling calender.

The sheets are placed in overlapping relationship on the table IS withthe tapered irregular edge of one sheet disposed adjacent the face ofanother sheet and are so fed to the rolls of the cross-rolling calenderl1. As shown in Figure 1, such sheets are fed face-down so that theirregular edge is the rearward edge of the sheet. The sheets arecross-rolled to spread and shorten the graining and to form a continuousintegral sheet which may be placed upon a suitable backing or fed to thedies of the rotary inlaying machine as well-known in the industry.

The practice outlined above substantially or entirely eliminates thevisible discontinuity between overlapped sheets. Distortion of facegraining at the overlapped edges does not occur to any substantialextent and accordingly, a continuous variegated linoleum sheet isproduced in which the graining presents substantially the desiredappearance over the face of the sheet. The enormous waste created byhook-on i entirely eliminated and a more desirable and decorative sheetis produced. The improvements in the cross-rolling process abovedescribed add little or nothing to the costs involved in making thesheet. The additional apparatus required in order to effectuate suchimprovements is inexpensive and does not require frequent replacement.Needless to say, however, the chief advantage of my improved processresides in the substantial or entire elimination of grain distortion atthose sections of the continuous sheet where overlapped sheets areadhered to one another.

While I have described and illustrated a preferred embodiment of myinvention, it will be understood my invention is not so limited since itmay be otherwise embodied or practiced within the scope of the followingclaims.

I claim: 1. In the method of making variegated hard surface coverings,the steps comprising forming a vari-colored mass of differently coloredgranular compositions, subjecting said mass to pressure to form a sheethaving a definite directional graining, forming a plurality of openingsin said sheet, tearing said sheet along the openings so as to form twosections, each section having an irregular edge formedof torn and formedportions, overlapping sections so that the irregular edge of one sectionis disposed adjacent the face of the other section, and calendering theoverlapped sections at an angle to the direction of graining to form acontinuous sheet.

2. In the method of making variegated hard surface coverings, the stepscomprising forming a vari-colored mass of differently colored granularcompositions, subjecting said mass to pressure to form a, sheet having adefinite directional graining, forming a plurality of equally spacedopenings in said sheet, tearing said sheet along the openings so as.toform two sections, each section having an irregular edge composed of tomand formed portions substantially equal in length, overlapping sectionsso that the irregular edge of one section is disposed adjacent the faceof the other 'secflon, and calendaring the overlapped sections at anangle to the direction of graining to'form a continuous sheet- 3. In themethod of making variegated hard surface coverings, the steps comprisingforming a vsri-colored mass of differently colored granularcompositions, subjecting said mass to pressure to form a sheet having adefinite directional graining,'forming a plurality ofeffect openings insaid sheet, tearing said sheet so as to connect the offset openingsthusseparating the sheet in two sections, each of said sections having anirregular cdse formed of alternate torn and formed portions, overlappingsections so that the irresular edge of one section is disposed adjacentthe face of the other section; and calendering the overlapped section atan angle to the direction of graining to form a continuous sheet.

4. In the method of making variegated hard surface coverings, the stepscomprising forming a vari-colored mass of differently colored granularcompositions, subjecting said mass to pressure to form a sheet having adefinite directional graining, skiving a portion of the under surface ofsaid sheet so as to decrease the thickness of the sheet at the skivedportion, forming a plurality of openings at the skived portion of saidsheet, tearing said sheet along the openings so as to form two sections,each section having an irregular edge formed of alternate torn and 1formed portions, overlapping sections so that the irregular tapered edgeof one section is disposed adjacent the face of the other section, andcalendering the overlapped sections at an angle to the direction ofgraining to form a continuous sheet.

5. In the method of making variegated hard surface coverings, the stepscomprising forming a vari-colored mass of differently colored granularcompositions, subjecting said mass to pressure to form a sheet having adefinite directional graining, skiving a portion of the under surface ofsaid sheet so as to decrease the thickness of the sheet at the skivedportion, forming a plurality of offset openings at the skived portion ofsaid sheet, tearing said sheet so as to connect the offset openings thusseparating the sheet in two sections, each ofsaid sections having atapered,

a vari-colored mass of differently colored granular compositions,subjecting said mass to pressure to form a sheet having a definitedirectional graining, skiving a portion of the under surface of saidsheet so as to decrease the thickness of the sheet at the skivedportion, forming a plurality'of offset openings at the skived portion ofthe sheet, tearing said sheet to connect the offset openings thusseparating the sheet in two sections each of which possesses anirregular tapered edge formed of alternate torn and formed portions andof less thickness than the remainder of the section, subdividing saidsections into sheets of predetermined size so that an edge of each sheetis formed from the irregulare e of the section, overlapping saidsubdivided sheets so that the irregular edge of one sheet is disposedadjacent the face of a second sheet, and

calendering the overlapped sections at an angle to the direction ofgraining sheet. v

7. In the method of forming a variegated sheet of hard surface coveringby a cross-rolling operation, the steps which comprise formingavplurality of similar sheets each having an irregular to form acontinuous edge formed of substantially alternately formedand tornportions, overlapping said sheets so that the irregular edge of onesheet i disposed adiacent the face of a second sheet, and (Bl-0889MB- 8said sheets to form a continuous sheet.

ARHNGTON 0. PERRY.

